DEPARTMENT OF PRODUCTION ENGINEERING

Yam (Dioscorea spp.) remains a major staple and economic crop in Nigeria, where it serves as a vital source of food and income. However, traditional yam processing methods involving manual pounding are time-consuming, labor-intensive, and unhygienic, making them unsuitable for large-scale or commercial production. This study focuses on the design, fabrication, and performance evaluation of an automated yam blending machine with an emphasis on minimizing material leakage—a common limitation in existing models. The machine was designed using mechanical and food engineering principles to achieve efficient blending through an electrically powered motor, stainless-steel blending chamber, and an effective sealing system that prevents leakage. Locally sourced materials were used to enhance affordability and promote indigenous technology. Performance evaluation showed that the machine successfully pounded 500 g of boiled yam within an average of 2.7 minutes, achieving an output efficiency of 97% and a throughput capacity of 16.18 kg/hr

Poultry farming is a crucial agricultural sector that provides protein and economic opportunities, particularly in rural communities. However, small-scale poultry farmers often face challenges in egg incubation due to unreliable electricity and the high costs of conventional incubators. This study explores the design, fabrication, and evaluation of a solar-powered egg incubator tailored for small-scale poultry farmers. The proposed incubator harnesses renewable solar energy to maintain optimal incubation conditions, ensuring stable temperature, humidity, and automated egg turning. The research employs a systematic approach, including component selection, design calculations, computer-aided design (CAD) simulations, and prototype fabrication. The incubator is designed to be cost-effective, energy-efficient, and scalable, making it accessible to farmers in off-grid areas. Performance tests demonstrated that the incubator maintained an internal temperature range of 37–38°C, achieving a hatchability rate of 91% and a fertility rate of 95%. Computational
Fluid Dynamics (CFD) analysis validated its thermal efficiency and air circulation patterns. The results indicate that solar-powered incubation is a viable alternative to conventional methods, reducing dependency on fossil fuels while enhancing productivity. This study contributes to sustainable poultry farming by offering a practical, environmentally friendly, and economically viable solution for small-scale farmers. Further research is recommended to explore large-scale applications and the integration of automated control systems

This study investigates the simulation of the actual maximum stress in Tungsten Inert Gas (TIG) weldment using SIMUFACT Welding software. The research aimed to compare the simulated stress values with experimental results obtained in a controlled environment under varying process parameters such as current, voltage, and gas flow rate. During the design of experiment, twenty experimental runs was generated by the Central composite design and it was used to carry out TIG welding on mild steel plates. A universal testing machine was used to record the actual maximumm stress on the welded joint and recorded as experimental values. The data generated from the CCD matrix was then feed into an expert system (SIMUFACT 2024) which was used to carry out TIG welding simulations with its corresponding actual maximum stress recorded alongside as the SIMUFACT result.
Results from this study revealed that that increasing welding current reduces the maximum stress due to higher heat input and lower cooling rate, while voltage variation influences arc width and stress distribution. The actual maximum stress values from both datasets were analyzed and compared. The results revealed close agreement between experimental and simulated values, a fitted line plot was used to ascertain the degree of correlation between both results and a correlation coefficient of 0.98 was observed, indicating a very strong positive correlation degree between the experimental result and the SIMUFACT result. A time series plot was then used to compare if both data sets assumed the same trend. The SIMUFACT welding simulation analysis proved to be a reliable tool for simulating and predicting the actual maximum stress in TIG-welded joints thereby aiding in the optimization of welding parameters for an improved structural integrity.

Yam (Dioscorea spp.) remains a major staple and economic crop in Nigeria, where it serves asavital source of food and income. However, traditional yam processing methods involvingmanual pounding are time-consuming, labor-intensive, and unhygienic, making themunsuitableforlarge-scale or commercial production. This study focuses on the design, fabrication, andperformance evaluation of an automated yam blending machine with an emphasis on minimizingmaterial leakage—a common limitation in existing models. The machine was designed using mechanical and food engineering principles to achieveefficient blending through an electrically powered motor, stainless-steel blending chamber, andan effective sealing system that prevents leakage. Locally sourced materials were used to enhance affordability and promote indigenoustechnology. Performance evaluation showed that the machine successfully pounded 500gofboiled yam within an average of 2.7 minutes, achieving an output efficiency of 97%andathroughput capacity of 16.18 kg/hr. The pounded yam produced exhibited excellent textural qualities comparable to traditionallyprepared samples. The developed machine demonstrated improved hygiene, ease of operation, and significant reduction in processing time, thereby offering a viable solution for householdandsmall-scale commercial yam processing. This innovation contributes to Nigeria’s local equipment fabrication efforts and enhances food processing mechanization.

Welding is an essential fabrication process in various industries, including automotive, aerospace, shipbuilding, and construction. It is a method used to join metals or thermoplastics through coalescence, usually involving the application of heat or pressure. The welding of similar metals, such as steel-to-steel or aluminum-to-aluminum, is relatively well-understood, with established techniques and filler materials to ensure strong and reliable welds. However, welding dissimilar metals (those with different chemical compositions and physical properties) introduces additional challenges due to the inherent differences in melting points, thermal conductivity, and expansion rates.Dissimilar metal welding (DMW) has gained increasing attention in recent years due to its potential to optimize material properties in critical applications. For instance, in the automotive industry, lightweight materials like aluminum are welded to stronger metals such as steel to produce fuel-efficient vehicles without compromising safety. In the aerospace industry, DMW enables the combination of materials like titanium and aluminum, offering a balance between strength, heat resistance, and weight reduction.The role of filler materials is particularly important in DMW, as they act as intermediaries between the base metals, helping to form a stable joint. The choice of filler material influences not only the mechanical strength of the weld but also its resistance to corrosion, heat, and stress. Incompatible filler materials can lead to poor weld strength, the formation of brittle intermetallic compounds, or cracking. This study seeks to explore how different filler materials affect weld strength in DMW, with the ultimate goal of identifying the optimal materials for specific dissimilar metal combinations.

This project centers on devising a cost-efficient and highly productive solution for the palm oil industry, with a specific focus on alleviating the labor-intensive palm kernel cracking process. The proposed machine incorporates cutting-edge design principles and advanced materials to elevate its performance and reliability. By subjecting the project to rigorous engineering analysis and prototyping, the primary objective is to attain the utmost efficiency in kernel cracking while
concurrently minimizing waste and energy consumption. Furthermore, the design prioritizes safety, environmental consciousness, and scalability. The successful execution of this project holds the potential to transform the palm oil industry by simplifying the kernel extraction procedure, ultimately ushering in heightened productivity and sustainability within the sector.

Every organisation aims at profit maximization and growth. Growth and profits are directly related to the level of satisfaction that is imparted by the product or the services to the customers. Customer wants value for money. He wants the best quality in the given cost. So how does an organisations achieve this quality? Quality is a subjective constraint. Every
customer has a different taste of quality. So, it is the job of the organisation to provide everything in terms of quality that every customer demands. So, from where does this quality start? It starts from the moment the manufacturer purchases the raw material from the supplier.
This quality is percolated in the product through right set of processes, activities with the use of right resources in terms of human and technology and ultimately right quality is achieved by reduction in defect in the product. Lesser is the tolerance limit for defect, better is the quality.
This concept drives the organization towards the concept of least deviation in the products that are manufactured. This drives the organisation towards Six-Sigma. Two of the most popular continuous improvement programs are Six Sigma and lean management. Six Sigma was founded by Motorola Corporation and subsequently adopted by many US companies, including General Electrical GE and Allied Signal. Lean management originated at Toyota in Japan and has been implemented by many major US firms, including Danaher Corporation and HarleyDavidson. Six Sigma and lean management have diverse roots, (Arn Heiter and Maley Eff, 2005). management (TQM) and just-in-time (JIT), (Naslund, 2008). Both Six Sigma and lean management have evolved into comprehensive management systems which clarify in lean six sigma methodology. In each case, their effective implementation involves cultural changes in
organizations, new approaches to production and to servicing customers, and a high degree of training and education of employees, from upper management to the shop floor. As such, both systems have come to encompass common features, such as an emphasis on customer
satisfaction, high quality, and comprehensive employee training and empowerment, (Arn Heiter and Maley Eff, 2005). Some elements to eliminate many misconceptions regarding Six Sigma and lean management by describing each system and the key concepts and techniques
that underlie their implementation, (Arn Heiter and Maley Eff, 2005).

This project focuses on the upgrade of an electric bicycle to enhance its performance and range. The objective is to improve the distance travelled and charging power of the
bicycle through technical enhancements and component upgrades. Methods include the integration of advanced battery technology, indication upgrade, and enhancements to
the control systems. Results demonstrate significant improvements in speed, range, and overall user experience. The findings of this project contribute to the advancement of electric bicycle technology, offering insights into potential upgrades for future models.

The project titled “Design and Fabrication of a Grain Crusher” was aimed at developing a small-scale, electrically powered machine for crushing and grinding grains such as maize, millet, and sorghum into finer particles for easy processing. The objectives were to design a hammer mill-type crusher suitable for local use, ensure ease of maintenance, minimize power consumption, from locally sourced materials. The methodology involved conceptual design, material selection, component fabrication, and
assembly of the crushing unit, hopper, frame, and power transmission system. Key design parameters such as shaft diameter, pulley ratio, hammer dimensions, and motor power were determined using standard mechanical design equations. erformance evaluation was conducted through test runs using maize to assess crushing efficiency and particle size distribution.

Welding is the process to join two or more similar or dissimilar metal with the applicationofheat and sometime pressure. Gas Tungsten Arc Welding (GTAW) is commonly knownasTungsten Inert Gas Welding (TIG Welding). Corrosion of metal is an ubiquitous phenomenonthat occurs in various forms. Atmospheric or uniform, galvanic, crevice, pitting, and microbial corrosion are most familiar forms of corrosion. The service life of engineering structuresisaffected by the quality and strength of the welded joints. The effects of corrosion affects thequality of the welded joints and the general structure. The offshore structures are exposedtothevarious environments, and it is well known that the corrosion rate and the corrosion mechanismunder each environment, marine atmosphere, splash zone, tidal zone, underwater zoneandbottom zone, are different. The aim of this study is to model the environmental effectsofcorrosion on tungsten inert gas weld joints of a mild steel pipe using response surfacemethodology. Mild steel pipe was cut into dimension 40mm in length, 12mm diameter and 3mmthickwithapower hacksaw, grinded and cleaned before the welding process. The experimental matrixwasmade of twenty (20) runs, generated by the design expert software adopting the central composite design. The response was measured, which is the rate of corrosion and then modelledusing the response surface methodology. The result obtained in this study shows that the current has a very strong influence on the rateofcorrosion. Based on the findings, it is summarized that the corrosion rate is minimumwhenawelding voltage of V = 18V, current = 120A and gas flow rate = 13lit/min. The response surfacemethodology employs certain statistical tools which are Anova, goodness of fit, coefficient ofdetermination and noise to signal ratio which determines the adequacy and significance of themodel developed. The result from this study shows that the model has a very good varianceinflation factor and p-value < 0.05. The model posseses favourable coefficient of correlation(R)value for the rate of corrosion